Method for making a tapered edge elastomeric sheet, tapered edge elastomeric sheet, and method of sealing a gap or split joint by applying and adhering such a tapered edge elastomeric sheet

Abstract

A polygonal elastomeric barrier sheet has tapered edges on at least two adjacent sides. At least one of the tapered edges is made by cutting the elastomeric barrier sheet along a cutting line at an angle of at most 15° to the plane of the sheet. The elastomeric barrier sheet is supported during the cutting step to prevent distortion due to the pressure of the cutting blade. The elastomeric barrier sheet can be supported from above, from below, or both from above and below, and can be supported on each side of the cutting line. The polygonal barrier sheet so produced is useful in construction and building to seal gaps between structural elements, such as expansion or control joints in a building, or around functional elements, such as windows or doors, inserted in a wall.

Description

Background Technology

[0001] The present invention relates to tapered edge elastomer sheets, methods for manufacturing such tapered edge elastomer sheets, and uses of tapered edge elastomer sheets, including as barrier materials for sealing openings between adjacent building structural elements.

[0002] Structural elements (such as windows and doors) are typically inserted into rough openings in the building structure. These rough openings are typically slightly larger than the inserted structural element to allow for easy installation. This creates gaps between the structural element and the building structure. These gaps must be sealed to prevent air and water from penetrating the building. Sealing can be achieved by installing backing bars and filling the gaps or by installing insulating foam, but these methods are time-consuming, require skilled workers, and are unsatisfactory when the gaps are large or their size changes over time due to fluctuations in environmental conditions such as temperature and humidity.

[0003] Alternatively, gaps can be sealed by applying an elastomeric sheet to the gap and adhering it to the appropriate location on the inserted structural element and the wall or surrounding building framing. These elastomeric sheets need to be robust enough to withstand damage during installation. They must also be able to accommodate movement of the building framing members and / or the inserted structural elements throughout the building's lifespan. This movement can be caused by a variety of factors, such as thermal expansion and contraction, settlement of the building and / or the ground floor, seismic events, and shock and / or acoustic events. In some cases, this movement can be quite significant. Furthermore, the seal must remain intact for a considerable period when exposed to environmental stresses, including high and low temperatures, water, snow and ice, ultraviolet radiation, and insects and other pests. These requirements necessitate that the elastomeric sheet be quite robust and made of resins based on silicone, polyolefins, polyurethane, and other polymer backbones. Thinner, lower-performance films (such as flash tape and building protection films) typically lack the necessary mechanical properties and long-term durability required for this service.

[0004] Taking these mechanical and durability issues into account during the design process, elastomeric sheets have proven difficult to lay evenly, especially at corners where the elastomeric sheets themselves are folded or overlapped. When the elastomeric sheets have the thickness, mechanical properties, and durability required in this application, it is difficult to achieve a good seal at overlap points.

[0005] PCT / US2023 / 018623 describes a method for solving sealing problems at overlaps by providing self-adhesive barrier sheets characterized by tapering at one or both of the sheet's two opposite edges. However, two problems remain. One problem is how to manufacture them efficiently and cost-effectively. PCT / US2023 / 018623 describes several techniques for producing rolls of continuous elastomeric sheets with tapered edges, including cutting methods, casting and molding techniques, and extrusion of profile sheets using specially shaped slot dies; however, molding and extrusion methods are expensive, time-consuming, and inflexible. Another problem is that while the barrier sheets of PCT / US / 2023 / 018623 can be used to reduce gaps at corner overlaps with an angle of approximately 90 degrees between sheets, they are less effective at eliminating gaps at collinear lap joints or splice joints. Therefore, further improvements are desired.

[0006] U.S. Patent No. 4,806,400 describes forming a tape with a tapered edge, which can be used to wrap underground pipes to prevent corrosion. A cutter roller assembly is used to make continuous cuts along the lateral edge of the tape. The roller has spaced-apart grooves, each associated with a cutter. The cutter blade extends into the associated groove, pushing the tape into the groove and deforming the tape during slitting, causing shearing and stretching to occur simultaneously. The tapered angle of this cut differs from the angle formed by the cutter and roller when the device is used to form tapered edges on non-elastomeric polyethylene sheets. Summary of the Invention

[0007] In one aspect, the present invention is a method for producing a tapered edge in a non-porous elastomer sheet with a thickness of 0.8 mm to 2.5 mm, the method comprising cutting the non-porous elastomer sheet with a blade at a cutting angle of 15 degrees or less between the plane of the sheet and the blade, wherein the cutting is performed along a cutting line, wherein the blade is oriented toward the non-porous elastomer sheet at the cutting angle while supporting the non-porous elastomer sheet to prevent the non-porous elastomer sheet from deforming at the cutting line due to pressure from the blade against the non-porous elastomer sheet.

[0008] This invention offers several advantages. It can produce precise, acute-angled tapered edges. Unlike extrusion processes, this process is easily adaptable to manufacturing barrier sheets with three, four, or even more tapered edges. Extrusion processes are easily adaptable to produce tapered edges along the longitudinal machine direction, but not tapered lateral edges. Furthermore, unlike extrusion processes, this process is easily adaptable to producing sheets of arbitrary width and length, which produce sheets with a fixed width based on the dimensions of the extrusion die. Moreover, the method of this invention can be performed partially or entirely on-site, allowing the barrier material to be cut to the length and / or width required for a specific application.

[0009] In a second aspect, the present invention is a polygonal barrier sheet comprising a non-porous elastomer sheet with a glass transition temperature not greater than -40 °C, the non-porous elastomer sheet having a central region with a thickness of 0.8 mm to 2.5 mm, the central region being defined by an edge comprising at least a pair of adjacent edges, wherein each of the pair of adjacent edges is tapered to form an included angle of not more than 15 degrees in each of the adjacent edges.

[0010] A key advantage of the polygonal barrier sheet of the present invention is that it is well-suited for forming both cross joints and splice joints, at which it provides a good seal.

[0011] The present invention is also a method for sealing gaps between adjacent building components in a building structure, the method comprising applying and adhering a polygonal barrier sheet of the second aspect of the invention to the adjacent building components to span the gap with the polygonal barrier sheet.

[0012] In a particular aspect, the present invention provides a method for sealing a gap joint between a building structure and an insert positioned within an opening in the building structure, the method comprising:

[0013] The polygonal barrier sheet of the second aspect of the invention is applied to the insert and the building structure to span the slit joint, whereby one of the tapered edges of the polygonal barrier sheet is adhered to the insert by means of an adhesive applied to the opposite tapered edge, and the opposite tapered edge of the polygonal barrier sheet is adhered to the building structure by means of an adhesive applied to the other opposite tapered edge.

[0014] The method of this invention has the advantages of easy and inexpensive installation. The polygonal barrier sheet is simply cut to a certain length and applied. Pressure-sensitive adhesive can be pre-applied to the polygonal barrier sheet for easy application, or applied on-site at the application point if needed. Good sealing can be achieved at both lap joints and splice joints.

[0015] This invention offers additional significant advantages during installation: individual segments of self-adhesive barrier sheets are applied and overlapped at an angle, wherein the overlapping segment of the first self-adhesive barrier sheet is applied to the overlapping segment of the second self-adhesive barrier sheet by crossing over at least one tapered edge of the overlapping segment of the second self-adhesive barrier sheet. The tapered edge of the overlapping self-adhesive barrier sheets allows for minimizing or eliminating gaps along the intersection line of the two barrier sheets, thereby allowing for a tight seal with reduced or no leakage, and eliminating the need for separate sealing of the intersection point. The flexible sheet with a thicker central segment maintains the mechanical properties and durability required for these sealing products. The tapered edge also facilitates good sealing around overlaps and splices. Attached Figure Description

[0016] Figure 1 This is a top view of an embodiment of the polygonal barrier sheet of the present invention.

[0017] Figure 2A It is along Figure 1 The side view section diagram taken by arrow 2A.

[0018] Figure 2B This is a side cross-sectional view of an alternative embodiment of the polygonal barrier sheet of the present invention.

[0019] Figure 3A It is along Figure 1 The cross-sectional view taken by arrow 3A.

[0020] Figure 3B This is a side cross-sectional view of an alternative embodiment of the polygonal barrier sheet of the present invention.

[0021] Figure 4 This is a side cross-sectional view of the polygonal barrier sheet of the present invention, which has an attached adhesive layer.

[0022] Figure 4A yes Figure 4 Another cross-sectional view of the polygonal barrier sheet.

[0023] Figure 5 This is a cross-sectional view illustrating an embodiment of the cutting process of the present invention.

[0024] Figure 5A This is a cross-sectional view illustrating another embodiment of the cutting process of the present invention.

[0025] Figure 6 Is it like this? Figure 5 The diagram shows a perspective view of an embodiment of the cutting process of the present invention.

[0026] Figure 7This is a perspective view of another embodiment of the cutting process of the present invention.

[0027] Figure 8 It is a top view of the building structure, wherein the gaps between adjacent building components are sealed with polygonal barrier sheets of the present invention, which form overlapping joints.

[0028] Figure 8A It is along Figure 8 The cross-sectional view of the lap joint shown is taken by arrow 8A.

[0029] Figure 9 This is a cross-sectional view of a collinear lap joint formed using the polygonal barrier sheet and the second overlapping barrier sheet of the present invention.

[0030] Figure 10 It is a top view of the building structure, wherein the gaps between adjacent building components are sealed with polygonal barrier sheets of the present invention, which form splice joints.

[0031] Figure 10A It is along Figure 10 The cross-sectional view of the splicing joint shown is cut off by arrow 10A. Detailed Implementation

[0032] Turn Figure 1 , Figure 2A and Figure 2B The polygonal barrier sheet 1 includes a central region 2 with a thickness T. T is from 0.8 mm to 2.5 mm, preferably at least 1.0 mm or 1.25 mm, preferably up to 2.0 mm or up to 1.75 mm. As shown, the central region 2 is defined by opposite lateral edges 3 and 3A and opposite end edges 4 and 4A. Both lateral edges 3 and 3A and end edges 4 and 4A are adjacent. Figure 1 In the specific embodiment shown, both lateral edges 3 and 3A and both end edges 4 and 4A are tapered, as... Figure 2A and Figure 3A As shown. It is also within the scope of this invention that only one pair of adjacent edges is tapered. For example, only one of the lateral edges 3 and 3A and only one of the end edges 4 and 4A may be tapered. Edges 3, 3A, 4, and 4A are... Figure 1 The embodiments shown are straight, but any or all of these edges may alternatively be curved.

[0033] like Figure 1The polygonal barrier sheet 1 shown is quadrilateral (particularly rectangular), but not necessarily quadrilateral. The polygonal barrier sheet 1 can alternatively have any number of edges, such as 3, 4, 5, 6, 7, 8, or more. The angle formed by adjacent edges of the polygonal barrier sheet can vary from 90° by any amount, as may be required for a particular application, even if the polygonal barrier sheet 1 is quadrilateral. Generally, it is preferred that the polygonal barrier sheet has a pair of opposite edges that are not adjacent to each other. For example... Figures 1 to 4A In some embodiments shown, the opposing edges include a pair of lateral edges parallel to each other and a pair of end edges, each end edge adjacent to at least one lateral edge. The end edges may be parallel to each other or may not be parallel to each other, as a particular application may require or desire. For example, when used to seal certain inserts whose shape may be circular, pentagonal, or otherwise different from rectangular, the end edges may be cut at different angles to facilitate the formation of overlaps and / or splices between different multiple polygonal barrier sheets positioned around the insert.

[0034] like Figure 2A As shown, the lateral edges 3 and 3A are tapered, each having included angles α and α'. α and α' can be the same (as shown) or different. Each included angle is at most 15 degrees, preferably 5 to 12 degrees.

[0035] exist Figure 2A In the middle, the lateral edges 3 and 3A each taper inward from the bottom side 6 towards the top side 7, thus creating a trapezoidal cross-section. Figure 2B In the alternative embodiment shown, the lateral edge 3 tapers inward, while the lateral edge 3A tapers outward from the bottom side 6 toward the top side 7, thereby creating a rhomboid cross section.

[0036] In another embodiment (not shown), the lateral edges 3 and 3A each taper outwards.

[0037] like Figure 3A As shown, the end edges 4 and 4A each taper inwards, having included angles β and β' respectively, thus creating a trapezoidal cross-section. β and β' can be the same (as shown) or different. Each included angle is at most 15 degrees, preferably 5 to 12 degrees. Figure 3B In the alternative embodiment shown, the lateral edge 4A tapers inward from the bottom side 6 to the top side 7, and the lateral edge 4 tapers outward from the bottom side 6 to the top side 7 to create a diamond-shaped cross-section. Both the end edges 4 and 4A can taper outward if desired.

[0038] The widths of the lateral tapered edges 3 and 3A and the terminal tapered edges 4 and 4A can each be, for example, from 1 mm to 25 mm or greater. In some embodiments, the widths of the lateral tapered edges 3 and 3A and the terminal tapered edges 4 and 4A are each at least 3 mm or at least 5 mm, and up to 20 mm or up to 15 mm.

[0039] The thickness of the polygonal barrier sheet 1 at the outer endpoints 8 of the tapered lateral edges 3 and 3A and the outer endpoints 9 of the tapered end edges 4 and 4A (see, for example, see...). Figure 1 The size should be as small as possible (but practically feasible), preferably no greater than 0.1 mm, no greater than 0.05 mm, or no greater than 0.01 mm.

[0040] like Figures 1 to 3B As shown, the polygonal barrier sheet 1 is composed of a single layer of non-porous elastomer material, as described more fully below. In, for example... Figure 4A and Figure 4 In the alternative embodiment shown in B, the polygonal barrier sheet 1 comprises a non-porous elastomer sheet and further includes an adhesive layer 1B. Figure 4A and Figure 4 As shown in Figure B, the lateral edges 110 and 110A and / or the end edges 111 and 111A of the adhesive layer 1B may optionally taper in the same manner as the lateral tapered edges 3 and 3A and the end tapered edges 4 and 4A of the non-porous elastomer sheet 1A. This embodiment can be produced, for example, by first applying the adhesive layer 1B to the non-porous elastomer sheet 1A and simultaneously cutting one or more of the lateral and end edges of both the adhesive layer 1B and the non-porous elastomer sheet 1A to produce the desired taper.

[0041] Alternatively, adhesive layer 1B may not be tapered, in which case it preferably extends at most to the outer endpoints 8 of the lateral tapered edges 4 and 4A and at most to the outer endpoints 9 of the terminal tapered edges 3 and 3A. Adhesive layer 1B may be discontinuous and may not cover the entire main surface of the non-porous elastomer sheet 1A. For example, adhesive layer 1B may be applied only to the lateral tapered edges 4 and 4A and / or the terminal tapered edges 3 and 3A. Adhesive layer 1B in Figure 4 and Figure 4A The layer 1B is shown as being applied to the bottom side of the nonporous elastomer sheet 1A; in other embodiments, the adhesive layer 1B may be applied alternatively or additionally to the top main surface of the nonporous elastomer sheet 1A, and as previously described, may be discontinuous or continuous, and may be applied only to the lateral and / or end tapered edges. The lateral and / or end edges of any adhesive layer 1B applied to the top side of the nonporous elastomer sheet 1A may or may not tape in the same manner as the nonporous elastomer sheet 1A.

[0042] At least one tapered edge of the non-porous elastomer sheet is formed by cutting the sheet at a cutting angle of 15 degrees or less. The cutting step is performed along the cutting line, wherein the blade is oriented at the cutting angle toward the non-porous elastomer sheet. The cutting line can be straight or curved. The non-porous elastomer sheet is supported to prevent deformation at the cutting line due to the action of the blade against the sheet. The non-porous elastomer sheet is preferably supported from below and additionally from above during the cutting step. Figure 5 and Figure 6 As shown, the non-porous elastomer sheet is preferably supported from above on each side of the cut line, and also from below.

[0043] exist Figure 5 and Figure 6 In the process, the non-porous elastomer sheet 10 is cut along the cutting line 13 using a blade 16 to produce a tapered end edge 4 with an included angle β. The non-porous elastomer sheet 10 is supported by a lower support member 15. Figure 5 It is supported from below, and this support can be, for example, a desktop, tabletop, or any other rigid surface. Figure 5 As shown, the lower support 15 extends close to the cutting line 13. A second lower support (not shown) may be provided on the opposite side of the blade 16 and the cutting line 13 (as shown, on the left).

[0044] exist Figure 5A In the specific embodiment shown, the upper supports 11 and 12 are positioned to contact the upper surface 17 of the non-porous elastomer sheet 10 on both sides of the blade 16 and the cutting line 13. The supports 11 and 12 hold the non-porous elastomer sheet 10 against the lower support 15, close to the cutting line 13, and thereby reduce movement of the elastomer sheet 10 during cutting by the blade 16, thus preventing deformation of the non-porous elastomer sheet during cutting. This ensures a clean and accurate cut at a defined angle.

[0045] like Figure 5 and Figure 6 As shown, the upper support members 11 and 12 ( Figure 5 ) and upper support members 11A and 12A ( Figure 6 ) takes the form of stabilizer bars, which are in the cutting direction (e.g. Figure 6 (As indicated by arrow 18 in the diagram) extends over the non-porous elastomer sheet 10. Either or both of the upper supports 11 and 12 (or 11A and 12A) may include angled surfaces that act as guides for the blade 16, thereby establishing an angle between the blade 16 and the non-porous elastomer sheet 10 to create an included angle β for the tapered edge 4. Figure 5 and Figure 5A In the specific embodiment shown, only the upper support 11 has this angled surface. Figure 6In the alternative embodiment shown, only the upper support 12A has this angled surface. In either embodiment, both upper supports may have this angled surface. The blade 16 is aligned with the angled surface of the upper support. The blade 16 is in Figure 6 It is shown as a circular rotating blade, but it can be a straight blade if desired.

[0046] For example Figure 5A In the illustrated embodiment, the blade 16 can extend through the non-porous elastomer sheet 10, enter and partially or completely pass through the replaceable sacrificial layer 19, such as Figure 5A As shown, the sacrificial layer 19 is partially or completely cut when cutting the non-porous elastomer sheet 10. This configuration is particularly useful for creating tapered end edge cuts in the field, where the sacrificial layer 19 can be a rubber cutting pad, scrap wood, or even cardboard. The sacrificial layer 19 supports the non-porous elastomer sheet 10 from below to prevent deformation at the cut line due to the pressure of the blade 16 against the non-porous elastomer sheet 10. The upper supports 11 and 12 support the non-porous elastomer sheet 10 from above to further prevent such deformation.

[0047] The upper supports located on both sides of the cutting blade can be connected at their ends to form a stabilizer assembly in which the distance between these upper supports is fixed.

[0048] exist Figure 6 In the illustrated embodiment, the non-porous elastomer sheet 10 already has tapered lateral edges 3A, and tapered end edges are produced by cutting along the cut line 13. In some embodiments, the tapered lateral edges are produced in the extrusion process, such that only the tapered end edges are produced by cutting. This allows elastomer sheets with tapered lateral edges to be produced continuously in fixed widths and indefinite lengths, which can be sold in rolls. A cutting step can then be performed in-situ to produce tapered end edges, cutting the sheet to any length that may be required, and producing inward or outward tapered end edges as needed.

[0049] In an alternative embodiment, all tapered edges are produced by cutting. The tapered lateral edges 3 and 3A can be produced by cutting a "master roll" of wide, non-porous elastomer sheet using a stationary slitting machine, wherein the slitting machine blades are set at an angle α to the starting non-porous elastomer sheet. Cutting is performed by moving the sheet through the stationary slitting machine. Embodiments of this process are described in... Figure 7 As shown in the image.

[0050] exist Figure 7In this process, a non-porous elastomer sheet 10 is fed from a master roll 20 and pulled through a slitting machine 23 by a power roller 22 or other equipment (such as a tensioning frame for moving the non-porous elastomer sheet 10). The slitting machine 23 includes bottom rollers 24 and upper rollers 25. The bottom rollers provide support for the non-porous elastomer sheet 10 from below near the cutting line, and the upper rollers provide support for the non-porous elastomer sheet 10 from above near the cutting line. The non-porous elastomer sheet 10 passes between the bottom rollers 24 and the upper rollers 25, each of which contacts either the lower surface (bottom roller 24) or the top surface (upper roller 25) of the non-porous elastomer sheet 10. The slitting machine 23 further includes blades 26 and 27, each of which is disposed between the two bottom rollers 24 and the two upper rollers 25, and each of these blades is positioned at an angle α to the non-porous elastomer sheet 10. The slitting machine 23 is stationary. The non-porous elastomer sheet 10 is cut into polygonal barrier sheets 1 with tapered lateral edges having an included angle α. Multiple slitting machines 23 can be provided, if desired, to simultaneously cut a wide non-porous elastomer sheet 10 into multiple polygonal barrier sheets 1, giving them various widths as needed. The tapered end edges can then be produced by cutting discrete pieces or segments from this roll, for example, as... Figure 5 , Figure 5A and Figure 6 As described in [the text].

[0051] In one particular embodiment, the cutting process is used to produce a polygonal barrier sheet having more than four sides. A quadrilateral non-porous elastomer sheet is produced having tapered lateral edges and end edges, which may also optionally be tapered. The tapered lateral edges can be produced in any convenient manner, including by extruding a non-porous elastomer sheet with tapered lateral edges, by cutting as described herein, or by other convenient methods. The tapered end edges (where present) are preferably produced by cutting as described herein. The quadrilateral non-porous elastomer sheet is cut once or multiple times with a blade at a cutting angle of 15 degrees or less between the plane of the sheet and the blade to produce additional tapered edges, thereby forming a polygonal sheet having more than four sides, wherein all sides have tapered edges with an included angle of 15 degrees or less.

[0052] "Non-porous" means that the elastomeric sheet contains no pores at all, or if the elastomeric sheet contains pores, those pores are not interconnected to create a fluid path from one main side of the non-porous elastomeric sheet to the other. The non-porous elastomeric sheet should be a barrier to liquid water, preferably leak-free for at least 30 minutes under a watertightness test according to EN1928:2000 Method B at a pressure of 0.3 kPa. The construction material used for the non-porous elastomeric sheet is preferably a polymer, which can be thermoplastic or thermosetting. The non-porous elastomeric sheet preferably has a maximum load elongation of at least 10%, preferably at least 50%, or at least 100%, as measured by ASTM D412. In a particularly preferred embodiment, the non-porous elastomeric sheet exhibits a Shore A hardness of at least 20 and at most 80 or at most 60 (ASTM D2240-15). Examples of suitable structural materials for nonporous elastomer sheets include elastomer materials such as silicone rubber, polyurethane rubber, polyester rubber, polyamide rubber, thermoplastic vulcanizates, polyolefin rubber, polymers and copolymers of diene monomers (such as butadiene, isoprene, and chloroprene) (including styrene / butadiene deblocking and triblock copolymers), nitrile rubber, and natural rubber. Nonporous elastomer sheets can be single-layer materials, composite materials, or multilayer co-extruded or laminated materials.

[0053] The polygonal barrier sheet of the present invention can be used to seal gaps between adjacent building components in a building structure. The gap is sealed by applying and adhering the polygonal barrier sheet of the present invention to adjacent components to span the gap with a self-adhesive barrier sheet. Typically, a lateral edge (usually a tapered lateral edge) of the polygonal barrier sheet is adhered to a first building component adjacent to the gap. Another edge (usually a tapered opposite lateral edge) of the polygonal barrier sheet is adhered to another adjacent component, such that the polygonal barrier sheet spans and covers the gap. A method for sealing gaps in a building structure using a barrier sheet with tapered edges is described in more detail in PCT / US2023 / 018623, which is incorporated herein by reference; this method applies herein.

[0054] When separate polygonal barrier sheets are overlapped to create lap joints or joined at splice joints, the tapered edges facilitate a good seal.

[0055] Figure 8 and Figure 8A An exemplary embodiment is shown in which two polygonal barrier sheets forming an overlapping joint are used to seal an intersecting gap. Building members 40, 41, 42, and 43 are arranged to create a horizontal gap 45 and a vertical gap 44, the horizontal gap being located between building members 40 and 41 and between building members 42 and 43, and the vertical gap being located between building members 40 and 42 and between building members 41 and 43.

[0056] The polygonal barrier sheet 50 includes a central portion 52 and opposite tapered lateral edges 53 and 53A. The tapered lateral edges 53 are adhered to building members 40 and 41 via an adhesive layer 47. The tapered lateral edges 53A are adhered to building members 42 and 43 via an adhesive layer 47A. The central portion 52 spans a gap 44.

[0057] The polygonal barrier sheet 30 includes a central portion 32 and opposite tapered lateral edges 33 and 33A. The tapered lateral edges 33 are adhered to building members 41 and 43 via an adhesive layer (not shown). The tapered lateral edges 33A are adhered to building members 40 and 42 via an adhesive layer (not shown). The central portion 32 spans a gap 45.

[0058] The overlapping portion of the polygonal barrier sheet 30 overlaps with the polygonal barrier sheet 50 to create an lap joint. The polygonal barrier sheet 30 extends across the tapered lateral edges 53, the center portion 52, and the tapered lateral edges 53A, and is adhered to them by an adhesive layer 49. (As shown in...) Figure 8A As can be seen, the presence of tapered edges 53 and 53A in the overlapping portion of the polygonal barrier sheet 50 eliminates the gap at the endpoints of the tapered lateral edges 53 and 53A, thereby improving the seal, as more fully described in PCT / US2023 / 018623.

[0059] Figure 9 A collinear overlap joint made of a polygonal barrier sheet 70 and a second barrier sheet 60 of the present invention, having tapered end edges 74, is shown. The second barrier sheet in this case has blunt end edges (i.e., no tapered end edges). The polygonal barrier sheet 70 includes a central portion 72 having tapered lateral edges (not shown) and tapered end edges 74. The polygonal barrier sheet 70 is adhered to a building member 48 via an adhesive layer 47. The second barrier sheet 60 is adhered to the building member 48 via an adhesive layer 46. The second barrier sheet 60 overlaps with the tapered end edges 74 and a portion of the central portion 72 of the polygonal barrier sheet 70, and is adhered to them via an adhesive layer 49. Due to the tapering of the end edges 74, gaps are eliminated at the points where the second barrier sheet 60 intersects with the polygonal barrier sheet 70.

[0060] Figure 10 and Figure 10AThis demonstrates the use of the polygonal barrier sheet of the present invention to create a splice joint. Building components 100 and 101 are arranged to create a gap 102. The first polygonal barrier sheet 110 of the present invention has a central portion 112, opposing tapered lateral edges 113 and 113A, and an inwardly tapered end edge 114A. The tapered lateral edges 113 and 113A are respectively adhered to building components 100 and 101 via an adhesive layer (e.g., adhesive layer 47). Figure 10A The central portion 112 of the first polygonal barrier sheet 110 spans and covers a portion of the gap 102.

[0061] The second polygonal barrier sheet 120 of the present invention has a central portion 122, opposite tapered lateral edges 123 and 123A, and an outwardly tapered end edge 124. The tapered lateral edges 123 and 123A are respectively adhered to building components 100 and 101 via an adhesive layer (e.g., adhesive layer 46). Figure 10A The central portion 122 of the second polygonal barrier sheet 120 also spans and covers a portion of the gap 102.

[0062] The outwardly tapered end edge 124 of the second polygonal barrier sheet 120 overlaps with the inwardly tapered end edge 114A of the first polygonal barrier sheet 110 to create a splice joint. Adhesive layer 49 adheres the outwardly tapered end edge 124 to the inwardly tapered end edge 114A. Figure 10A In the illustrated embodiment, in the area of ​​the splice joint, an optional additional adhesive 130 is applied to the exposed surfaces of the first polygonal barrier sheet 110 and the second polygonal barrier sheet 120. Figure 9 Unlike collinear lap joints, this type of splice joint provides a flat outer surface.

[0063] The gap to be sealed according to the invention can be defined by any two adjacent members of the building structure itself, which are spaced-apart portions, such as: i) gaps between frame members (e.g., columns, floors, ceilings, or roof joints or trusses); ii) gaps between wall or other partition sections; iii) gaps between floor or roof sections; iv) gaps between walls or other partitions and the floor or roof. The geometry of the gap is not critical, as long as it can be spanned by an elastomeric barrier sheet. Self-adhesive barrier sheets are particularly suitable for sealing gaps with widths from 1 mm to 500 mm, especially 25 mm to 300 mm or 50 mm to 300 mm.

[0064] The structural materials of a building are not limited, as long as an adhesive can form a bond with them. The portions of the building structure to which self-adhesive barrier sheets can be applied can be, for example, metals such as aluminum, steel, and copper; natural stone such as granite, marble, limestone, and slate; cementitious materials such as concrete, cinder blocks, and mortar; cast materials such as brick and ceramic tiles; processed products such as gypsum board; laminated insulation boards; wood products such as wood panels, plywood, and oriented strand board; artificial wood products; dense and / or foamed polymer products such as vinyl siding and insulation boards; and so on. Any of these structural materials can be coated with, for example, paint or another coating (such as an adhesion-promoting primer), or coated with a film (such as a moisture barrier or other protective film).

[0065] In some embodiments, the elastomeric barrier sheet is used to seal the gap between a building frame member and an insert positioned within an opening in the building frame member. This insert can be any structure inserted into the building structure for a functional, aesthetic, or other purpose. Other examples of inserts include windows; window frames; doors; door frames; lintels; fans; electrical panels; vents; slots for electrical, ducting, HVAC, or other conduits and / or cables; mailboxes or mail slots; access panels; frames or retainers for decorative elements; and so on. Inserts can be rectangular or any other shape, as may be used for their specific purpose.

[0066] The gap between the insert and the building frame member is sealed in the same general manner as other gaps as described above. The lateral edges of the polygonal barrier sheet are adhered to the insert by means of an adhesive applied to the lateral edges, and the opposite lateral edges of the polygonal barrier sheet are adhered to the building frame member by means of an adhesive applied to the opposite lateral edges. According to the invention, the lateral edges are preferably tapered to prevent gaps at the overlap of the barrier sheets. In some embodiments, the insert has a plurality of insert sides, each pair of adjacent insert sides defining a vertex, and a seam joint is defined by each of the adjacent insert sides and at least one side of the opening, and adjacent pairs of polygonal barrier sheets form an overlap joint at the vertex. In alternative embodiments, the insert has a plurality of insert sides, each pair of adjacent insert sides defining a vertex, and a seam joint is defined by each of the adjacent insert sides and at least one side of the opening. Adjacent pairs of polygonal barrier sheets with tapered end edges can form an angled splice joint at the point where the tapered end edges of adjacent polygonal barrier sheets overlap at the vertex.

[0067] The adhesive used for bonding the elastomeric barrier sheet is preferably pressure-sensitive. Examples of pressure-sensitive adhesives include silicone, acrylic, so-called "modified acrylic," and natural or synthetic rubber types. The adhesive is typically selected in conjunction with the choice of the flexible sheet and / or the building component to which the adhesive will be applied. Suitable pressure-sensitive adhesive products are widely available from sources such as 3M, Adhesive Applications, Dow Chemical, Elkem Silicones, Lohmann GmbH & Co., and SikaServices AG. The adhesive can be applied directly to the polygonal barrier sheet or provided as a tape applied to a portion or the entire surface of the polygonal barrier sheet. In a particular embodiment, the adhesive is in the form of a double-sided tape having two layers of pressure-sensitive adhesive coated on both sides of a carrier film. The two layers of pressure-sensitive adhesive can be the same or different; for example, one layer of pressure-sensitive adhesive can be selected for its bonding characteristics with the polygonal barrier sheet, while the other layer can be selected for its bonding characteristics with the building structure components. In one particular embodiment, one layer of pressure-sensitive adhesive may be of the silicone or "modified acrylic" type for bonding to a silicone polygonal barrier sheet, and the other layer may be of the general acrylic or natural or synthetic rubber type for bonding to a building structure.

[0068] Alternatively, the adhesive can be applied to the surface of the polygonal barrier sheet in liquid form, either as a solution or as a subsequently cured melt.

[0069] The thickness of the adhesive layer is preferably no greater than the maximum thickness of the polygonal barrier sheet, preferably no greater than 50% or 10% of the maximum thickness. In absolute terms, the thickness of the adhesive layer can be, for example, 0.01 mm to 0.75 mm, preferably 0.05 mm to 0.5 mm or 0.05 mm to 0.1 mm.

[0070] For packaging, storage, and / or transportation purposes, the adhesive layer applied to the polygonal barrier material prior to use may be covered with a protective film. Remove the protective film to expose the adhesive before installation.

[0071] Wall assemblies utilizing the barrier sheet of the present invention preferably conform to ASTM E2357: Standard Test Method for Determining the Air Leakage Rate of Air Barrier Components and / or ASTM D331-00 (Standard Test Method for Testing the Watertightness of Exterior Windows, Skylights, Doors and Curtain Walls by Uniform Static Pressure Difference). As specified in ASTM E283: Standard Test Method for Determining the Air Leakage Rate Through Exterior Windows, Curtain Walls and Doors at a Specified Pressure Difference on a Specimen, if such an assembly meets the standard of less than 0.04 cfm / sqft of infiltrated / leaked air at an air pressure of 1.57 psf, then the assembly is qualified as an air barrier assembly for both air infiltration and leakage.

Claims

1. A method for manufacturing a tapered edge in a non-porous elastomer sheet with a thickness of 0.8 mm to 2.5 mm, the method comprising cutting the non-porous elastomer sheet with a blade at a cutting angle of 15 degrees or less between the plane of the sheet and the blade, wherein, The cutting is performed along the cutting line, wherein the blade is oriented toward the non-porous elastomer sheet at the cutting angle, while supporting the non-porous elastomer sheet to prevent it from deforming at the cutting line due to the pressure of the blade against the non-porous elastomer sheet.

2. The method as described in claim 1, wherein, The non-porous elastomer sheet is supported from above and below during the cutting process.

3. The method as described in claim 1 or 2, wherein, The non-porous elastomer sheet is supported near the cutting line on opposite sides of the blade during the cutting process.

4. The method according to any one of claims 1 to 3, wherein, The non-porous elastomer sheet is supported by a stabilizing bar, which is applied to the top surface of the non-porous elastomer sheet near the cutting line.

5. The method according to any one of claims 1 to 4, wherein, The non-porous elastomer sheet is supported by two stabilizing bars, which are applied to the top surface of the non-porous elastomer sheet near the cutting line on opposite sides of the blade.

6. The method according to any one of claims 3 to 6, wherein, At least one stabilizer bar has an angled surface that defines the cutting angle, and the blade is aligned at the cutting angle by contacting the angled surface of the stabilizer bar.

7. The method according to any one of claims 1 to 6, wherein, The non-porous elastomer sheet is supported from below by a sacrificial layer, and the blade cuts the sacrificial layer and the non-porous elastomer layer along the cutting line at the cutting angle.

8. The method according to any one of claims 1 to 7, wherein, The nonporous elastomer sheet is a quadrilateral having a central region with a thickness of 0.8 mm to 2.5 mm, the central region being defined by a pair of opposite lateral edges and a pair of opposite end edges, and each pair of opposite lateral edges being tapered by moving the nonporous elastomer sheet through a fixed blade to produce a nonporous elastomer sheet with tapered lateral edges having an included angle of 15 degrees or less.

9. The method of claim 8, wherein, The fixed blade is mounted to a slitting machine, which further includes a bottom roller and an upper roller. The bottom roller provides support for the non-porous elastomer sheet from below, near the cutting line, and the upper roller provides support for the non-porous elastomer sheet from above, near the cutting line.

10. The method of claim 8 or 9, wherein, The non-porous elastomer sheet is in the form of a wide master roll, and the master roll moves through multiple fixed blades to produce multiple non-porous elastomer sheet strips with tapered lateral edges.

11. The method according to any one of claims 8 to 10, wherein, At least one of a pair of opposite end edges of the nonporous elastomer sheet having tapered lateral edges is subsequently cut to form tapered end edges with an included angle of 15 degrees or less.

12. The method according to any one of claims 1 to 8, wherein, The non-porous elastomer sheet is a quadrilateral with tapered lateral edges and optionally tapered end edges, and the quadrilateral non-porous elastomer sheet is cut once or multiple times with a blade between the plane of the sheet and the blade at a cutting angle of 15 degrees or less to produce a polygonal sheet with more than four sides, wherein all sides have tapered edges with an included angle of 15 degrees or less.

13. The method according to any one of claims 1 to 12, wherein, The non-porous elastomer sheet is composed of cross-linked silicone rubber, cross-linked polyolefin rubber, or cross-linked polyurethane rubber.

14. The method according to any one of claims 1 to 13, wherein, Prior to the cutting step, an adhesive layer is present on at least a portion of a main surface of the non-porous elastomer sheet.

15. The method of any one of claims 1 to 14, further comprising, after the cutting step, applying an adhesive layer to at least one tapered edge.

16. A polygonal barrier sheet comprising a non-porous elastomer sheet of a polymer with a glass transition temperature not greater than -40 °C, the non-porous elastomer sheet having a central region with a thickness of 0.8 mm to 2.5 mm, the central region being defined by an edge comprising at least a pair of adjacent edges, each of the pair of adjacent edges being tapered to form an included angle of not more than 15 degrees in each of the adjacent edges.

17. The polygonal barrier sheet as claimed in claim 16, wherein, The central region is defined by a pair of opposite lateral edges and a pair of opposite end edges, wherein at least one lateral edge and at least one end edge are tapered to form an angle of no more than 15 degrees in each of the at least one lateral edge and at least one end edge.

18. The polygonal barrier sheet as claimed in claim 17, wherein, Both opposite lateral edges taper to form an angle of no more than 15 degrees.

19. The polygonal barrier sheet as claimed in claim 18, wherein, The included angle between the tapered end edge and the included angle between the tapered lateral edge is no greater than 10 degrees.

20. The polygonal barrier sheet of claim 16, further comprising an adhesive layer applied to at least one side of each of the tapered edges, the thickness of the adhesive layer being no greater than the thickness of the central region of the non-porous elastomer sheet.

21. A method for sealing a gap between adjacent members in a building structure, comprising applying and adhering a polygonal barrier sheet as claimed in any one of claims 16 to 20 to the adjacent members to span the gap with a self-adhesive barrier sheet.

22. The method of claim 21, wherein, Separate first and second polygonal barrier sheets are applied and adhered to the adjacent member such that the first and second polygonal barrier sheets are aligned and their tapered end edges overlap to create a splice joint.

23. A method for sealing gaps between adjacent components in a building structure, comprising applying and adhering a first polygonal barrier sheet and a second polygonal barrier sheet as claimed in any one of claims 16 to 20 to the adjacent components to span one or more gaps between the adjacent components, such that the first polygonal barrier sheet and the second polygonal barrier sheet overlap at an angle to create an overlap joint, wherein the overlapping portion of the second polygonal barrier sheet is applied to the overlapping portion of the first polygonal barrier sheet by causing the overlapping portion of the second polygonal barrier sheet to lap over at least one tapered lateral edge of the overlapping portion of the first polygonal barrier sheet.

24. A method for sealing a gap joint between a building structure and an insert positioned within an opening in the building structure, comprising: A polygonal barrier sheet as described in any one of claims 16 to 20 is applied to the insert and the building structure to span the slotted joint, whereby the lateral edges of the polygonal barrier sheet are adhered to the insert by means of an adhesive, and the opposite lateral edges of the polygonal barrier sheet are adhered to the building structure by means of an adhesive.

25. The method of claim 24, wherein, The insert has a plurality of insert sides, each pair of adjacent insert sides defining a vertex, and a slotted joint is defined by each of the adjacent insert sides and at least one side of the opening, with individual polygonal barrier sheets applied to seal each of the slotted joints, each of the polygonal barrier sheets having tapered lateral edges, and adjacent pairs of the individual polygonal barrier sheets forming an overlap at the vertex.

Images